Edge guard

ABSTRACT

An insulated metal edge guard particularly adapted for fitting onto the trailing edge of a swinging closure which closes against an adjacent panel. The edge guard comprises a U-shaped metal channel having beads at the distal ends of the legs of the channel wherein the beads comprise double reversal folds folded back against the legs. Insulating material is selectively applied to the metal strip by an extrusion, or co-extrusion, procedure prior to the strip being formed into the channel-shaped cross section. Various embodiments of edge guard are disclosed.

REFERENCE TO A RELATED APPLICATION

This application is a continuation of Ser. No. 617,766 filed June 6,1984 now Pat. No. 4,565,032.

BACKGROUND AND SUMMARY OF THE INVENTION

This invention relates to an edge guard of the type which is commonlyapplied to the trailing edge of a swinging closure in an automotivevehicle. The disclosed embodiment is of a door edge guard which isinstalled on the trailing edge of a vehicle door.

Edge guards perform decorative and protective functions. Applicant hasoriginated and developed insulated metal edge guards wherein the edgeguards embody self-retention characteristics of a metal U-shaped channelwith the protective features provided by a layer of insulation on theinterior of the channel.

Edge guards of the type applied to the trailing edges of swingingclosures, particularly in the case of door edge guards, must be designedto fit the automobile manufacturers' door designs since the automobilemanufacturers themselves control the design of the doors.

Extensive body panel fit improvement programs conducted by automobilemanufacturers have reduced the thicknesses of the gaps between thetrailing edges of swinging closures and adjacent body panels. Forexample, in the case of a two-door vehicle, the gap between the trailingedge of each door and the adjacent quarter panel has been significantlyreduced as a part of this program.

In fact, one automobile manufacturer so designed its door fit that itwas impossible to provide edge guards as an original factory equipmentoption. This deprived the consumer of the availability of the decorativeand protective function of door edge guards, and it also resulted in alost opportunity for profit on the part of the automobile dealers andmanufacturers. If a customer desired a door edge guard it was necessaryfor the dealer to readjust the doors before the edge guards could beinstalled. This imposed a significant additional cost on the customerwhich could have been avoided if the edge guards could have beeninstalled at the factory as an original equipment option without dooradjustment.

The present invention is directed to a new and improved edge guard forthe trailing edge of a swinging closure which provides the protectiveand decorative functions of an insulated edge guard having aself-retaining metal channel, yet which is compatible with the reducedthickness gaps which are designed into the automobiles by themanufacturers, whereby an edge guard embodying principles of theinvention can be installed as an original equipment option at thefactory, if desired.

The present invention relates to an improvement in an edge guard whichrenders the edge guard suitable for use with automobiles having reducedthickness gaps between the trailing edges of its swinging closures andadjacent portions of the vehicle body. Moreover, the invention providesa construction which is efficient in its use of materials, yet providesfor a number of possible configurations depending upon the specificdesign deemed most appropriate for any particular vehicle.

The foregoing features, advantages, and benefits of the invention, alongwith additional ones, will be seen in the ensuing description and claimswhich should be considered in conjunction with the accompanyingdrawings. The drawings disclose a preferred embodiment of the inventionaccording to the best mode contemplated at the present time in carryingout the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial side elevational view of an automobile showing adoor having an edge guard embodying principles of the inventioninstalled on its trailing edge.

FIG. 2 is a cross sectional view on an enlarged scale taken in thedirection of arrows 2--2 in FIG. 1 and illustrating a first embodimentof edge guard according to the present invention.

FIGS. 3-16 respective views similar to FIG. 2, but of a somewhatschematic nature, illustrating various embodiments of edge guardsaccording to the present invention.

FIGS. 3A-16A are views each of which is correlated with a correspondingone of FIGS. 3-16 to illustrate in a schematic way a step in the methodof manufacturing the corresponding edge guard.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1 and 2 illustrate a door 20 containing a first embodident of edgeguard 22 installed on its trailing edge. When the door is in the closedposition, a gap 24 separates the trailing edge of the door from theforward edge of an adjacent vehicle body panel 26. In the case of atwo-door vehicle, the body panel 26 would be the vehicle quarter panel.Depending upon the styling of the vehicle, the edge guard may be otherthan straight, generally conforming to a contour or sweep correspondingto that of the trailing edge of the door. The length of the edge guardmay be less than or equal to the length of the trailing edge. Thevehicle body fit improvement programs referred to earlier have resultedin a reduced thickness for gap 24, and this gap is typically held tovery close tolerances. The present invention provides a door edge guardwhich can be used with these close gap tolerances.

Edge guard 22 is formed from a metal strip 28 into a generally U-shapedcross section comprising a curved base portion 30, an inner leg 32 andan outer leg 34 with the two legs extending from the curved base portion30. The metal strip may be of any suitable material of the type commonlyused for edge guard manufacture, for example stainless steel. The edgeguard comprises an exterior which is exposed for view and an interiorwhich confronts the trailing edge of door 20 in the manner shown.Although reference is made to the illustrated edge guard as having agenerally U-shaped cross section, it will be appreciated that principlesof the invention may be applied to other shapes such as J, V; moreover,it is not necessary that the legs be parallel, straight, or that theedge guard be symmetrical.

Edge guard 22 also comprises a layer of protective insulation 36 on theinterior of the metal channel. As can be seen in FIG. 2, the entireinterior of the metal channel fitting onto the door edge is covered byinsulation 36. This provides protection and other important features asexplained in many of applicant's issued patents and pendingapplications. The insulating layer extends from base portion 30 alonglegs 32, 34 to their distal ends, preferably far enough so that duringinstallation of the edge guard onto the door edge, the insulatingmaterial is always disposed between the metal of the U-shaped channeland the door edge. However, as can be seen from FIG. 2, the constructionof the edge guard is such that the metal is uncovered on the exterior soas to present a metallic appearance for view.

Edge guard 22 is further provided with beads 38, 40 respectively at thedistal ends of its legs. Each bead 38, 40 is formed as a doublethickness fold folded back onto the corresponding leg. The constructionof the edge guard is such that the distal ends of the legs areforce-applying points and therefore the triple metal thickness providedby the three thicknesses 42, 44, and 46 strengthens the edge guard forself-retention force-applying purposes. Yet the edge guard is compatiblefor the reduced thickness gap 24.

With the edge guard fitted fully onto the door edge in the manner shownin FIG. 2, the base of the edge guard clears body panel 26 when door 20is closed. In other words, the combined thicknesses of insulating layer36 and of metal strip 28 at base 30 are less than the thickness of gap24 which exists when the edge guard is not installed. Therefore, theedge guard is seen to fit onto the trailing edge of a swinging closurein a vehicle having a close tolerance gap between the trailing edge andan adjacent panel while it retains the beneficial self-retention,insulation, and protective characteristics of prior insulated edgeguards.

Although FIG. 2 illustrates the edge guard as fitting with conformityonto the trailing edge such that insulating liner 36 is in fullsurface-to-surface contact with the trailing edge of the door, it willbe appreciated that in actual practice this condition may not alwaysensue. There may exist a certain gap or space between the edge guard andthe door edge; however, a self-retention principle wherein theresiliency of the metal channel serves to exert a self-retention forcevia the distal ends of the legs is still maintained. It can therefore beappreciated that depending upon the design of the particular vehicle,cross sectional shapes other than the illustrated one may be used andyet still embody principles of the invention.

The remaining drawing FIGS. 3-16 and 3A-16A illustrate various specificembodiments of edge guards and steps in their manufacture. The preferredfabrication technique for making any of the edge guards is to extrudenon-metallic material, i.e. plastic such as vinyl, onto the metal stripin the flat. (FIGS. identified by the suffix "A") The extrusion may beon one side of the strip, both sides, and/or the longitudinal sideedges. Thus, the invention contemplates both single-sided anddouble-sided extruded, or co-extruded, laminates. The covering isselectively performed and may be either full or partial.

The extrusion, or co-extrusion, procedure is especially advantageousbecause it is possible to provide very precise control of the thicknessof the plastic material as well as its location. It is also possible touse known laser technology to provide precise control assuring theproper amount of plastic as far as size, gauge, and location and in bothsingle and double-sided laminates.

After the extrusion or co-extrusion of the plastic onto the metal stripin the flat, the laminate may be formed by conventional procedures intothe desired crosssectional shapes. The preferred procedure is by use ofroll-forming techniques. By the multiple folding to form a multi-dutchbend or a multi-bead at the distal end of each leg, in conjunction withthe characteristics of the particular metal selected for the strip, theresulting edge guard may be endowed with the desired attributes ofstrength and resilience, but while retaining a minimum thickness at thebase of the edge guard so as to accommodate the thickness of the gapbetween the trailing edge of the swinging closure and the adjacent bodypanel. Consequently, the invention yields a product which can be usedwith gaps having very close tolerances and heretofore unable to usefactory installed, or dealer installed edge guards without the necessityof a costly adjustment of the door.

In FIGS. 3-16 and 3A-16A, the broken lines represent insulation and thesolid line represents metal.

FIGS. 3A, 4A and 5A represent steps in the manufacture of thecorresponding edge guards 52, 54, 56 of FIGS. 3, 4, and 5 respectively.In each of these steps, insulating material is extruded only onto thesurface of the metal strip which forms the majority of the interiorsurface of the channel in the completed edge guard. This insulation willbe designated by the reference numeral 60 in these and the subsequentdrawing figures. FIGS. 3A and 3 correspond to the embodiment of edgeguard 22. The plastic material 60 is extruded onto a central region ofthe one side of the strip so as to leave the marginal longitudinal edgesof that surface of the strip free of insulation. After roll-forming, theinsulation lines the interior of the channel but does not extend anyappreciable extent around the distal ends of the legs.

In FIGS. 4 and 4A, the sizes of the margins which are left free ofinsulation are less than in FIGS. 3 and 3A whereby in the finished edgeguard the insulation covers the outer portions 46 of the threethicknesses so that the insulating material is visible from the exteriorat least along the distal margin of each leg.

FIGS. 5 and 5A illustrate a full covering of the one surface of themetal strip such that there is also a layer of insulating materialdisposed between the inner portion 44 and the corresponding leg. Thus,in this embodiment, the beads are fully covered with insulation.

FIGS. 6, 7 and 8 are respective embodiments 62, 64, 66 in whichinsulation 60 is extruded onto the interior surface of the metal stripin the same respective manners as for embodiments 52, 54, 56.Additionally, each of the three respective embodiments 62, 64, 66comprises a layer 68 of insulating material co-extruded on the side ofthe strip opposite layer 60. In these and subsequent embodiments, thereference numeral 68 will designate insulation applied to the surface ofthe strip opposite that to which insulation 60 is applied. The width ofthe insulation 68 is less than the width of the insulation 60; it does,however, fully cover the base and the legs on the exterior, extendingfrom the base at least to the beads.

Therefore, the embodident 62 of FIG. 6 presents an exterior appearancewhich is covered by insulation except at the beads.

The FIG. 7 embodiment 64 has the exterior substantially fully covered byinsulating material.

The FIG. 8 embodiment 66 is fully covered by insulating material.

FIGS. 9, 10, and 11 depict respective embodiments 70, 72, 74 wherein theinsulating material 60 is applied to the strip in the same manner as inFIGS. 3, 4, and 5 respectively, but wherein insulation 68 is co-extrudedonto the opposite surface of the strip to a greater extent than it wasin the embodiments of FIGS. 6, 7 and 8 respectively.

Each of the embodiments 70, 72, 74 presents an exterior appearancesubstantially the same as that provided by the embodiments of FIGS. 6, 7and 8. However, due to the greater width of the insulating layer 68 themarginal longitudinally extending side edges of the insulating materialon the exterior of the strip extend into the beads.

FIGS. 12, 13 and 14 are embodiments 76, 78, 80 having insulation on theinterior corresponding to FIGS. 3, 4 and 5 respectively. In embodiments76, 78, 80 the full extent of the opposite surface is covered byinsulation. Hence, embodiments 76, 78, 80 present exterior appearanceslike those of FIGS. 9, 10, and 11 respectively. The difference in theFIGS. 12, 13 and 14 embodiments is that a further thickness ofinsulation is imparted to each bead.

FIGS. 15 and 16 illustrate further embodiments 82, 84 which have adifferent shape for the double folds. In these embodiments the outerpart 86 of each fold is that portion of the metal strip which iscontinuous with the corresponding longitudinal edge of the strip. Inembodiment 82 of FIG. 15, insulation is applied to the full extent ofboth surfaces of the strip, and including the longitudinal side edges,and the strip is then formed to the illustrated cross section. Hence, itpresents an exterior appearance entirely of insulation.

FIG. 16 illustrates an embodiment similar to FIG. 15 but in which theinsulation is selectively applied to portions of the two sides of thestrip. Gaps 90, 92 are provided to control the number of thicknesses ofinsulating material at one of the beads.

In all embodiments, insulation is provided to line the interior in itsentirety, and while this is a preferred construction and is certainlyimportant at the force-applying points, it will be appreciated that theinvention can still be practiced without full insulation on theinterior.

Through the aforementioned techniques it is also possible to provideprecise control of the amount of plastic material extruded, orco-extruded, onto the metal strip. Thus it is possible to control thedimensions such as in the case of the selective covering of FIG. 16 sothat the desired final configuration will result. It is possible for thethickness of the insulating material to be non-uniform. It may bethicker at certain portions where desired and of a reduced thickness atother portions. For example, it may be considered desirable to taper thethickness in the vicinity of the base.

In many of the disclosed embodiments, the resultant construction at thedistal end of each leg comprises three thicknesses of metal and at leasttwo thicknesses of insulating layer wherein the two thicknesses ofinsulating layer are not in surface-to-surface confrontation with eachother but wherein one of the two thicknesses is disposed on the distalend of the leg so as to insulate the metal of the strip from that of thedoor. In some of these embodiments there may be more than twothicknesses of insulating material and in this way the insulatingmaterial may be used to control the overall thickness of the distal endof each leg.

The drawing illustrates the multi-beads as being in surface-to-surfacecontact, in other words fully closed. In actual practice it is possiblethat less than full closure of the beads may be employed.

An especially desirable attribute of the invention arises because it ispossible to co-extrude any desired color of plastic material onto themetal strip. By making the color the same as that of the painted doormetal, color matching is obtained. Hence, in the case of the reducedthickness gap, a color-matched edge guard enhances the appearance byde-emphasizing the gap.

An edge guard is manufactured by cutting the extruded, or co-extruded,laminate to a desired length. The longitudinal ends may therefore havebare metal showing. If this is objectionable it can be concealed byapplying paint, plastic, or other material to the end. A formed capcould also be fitted onto the end of the edge guard.

While a preferred embodiment of the invention has been disclosed, itwill be appreciated that principles of the invention are applicable tomultiple embodiments.

What is claimed is:
 1. In combination with the trailing edge of aswinging metal closure on a vehicle, which trailing edge in closedposition of the swinging metal closure, is separated from an adjacentpanel of the vehicle by a gap, an edge guard fitting onto the trailingedge comprising a metal strip formed into a channel having an interiorand an exterior and comprising a base and inner and outer legs extendingfrom said base for applying a self-retention force against oppositesides of the trailing edge, insulating means disposed between saidchannel and the trailing edge at least along the force-applying pointsof the legs for insulating the metal of the edge guard channel from thatof the trailing edge, and beads integral with and at the distal ends ofsaid legs, at least one of said beads comprising a double thickness foldof the metal strip folded back onto the corresponding leg so that threethicknesses of metal result at the force-applying point of that leg andwherein the combined thicknesses of said strip and of said insulatingmeans at said base are less than the thickness of said gap, and furtherincluding a non-metallic layer on the side of the strip which forms themajority of the exterior surface of the channel arranged so as to coverboth said base and the leg containing the bead having double thicknessfold at least to where the double thickness fold is folded back onto theleg.
 2. An edge guard as set forth in claim 1 in which said non-metalliclayer extends from said base far enough along the leg containing thebead having the double thickness fold so as to be disposed between saiddouble thickness portion and the leg.
 3. An edge guard as set forth inclaim 1 in which said insulating means extends from the interior of thechannel around the distal end of the leg containing the bead having saiddouble thickness fold so as to cover said double thickness portion onthe exterior of the channel.
 4. An edge guard as set forth in claim 3 inwhich said non-metallic layer comprises a color matching the color ofthe swinging metal closure.
 5. An edge guard as set forth in claim 1 inwhich said insulating means comprises a color matching the color of theswinging metal closure.
 6. An edge guard as set forth in claim 1 inwhich said insulating means comprises a layer of insulating materialadhered to the metal strip.
 7. An edge guard as set forth in claim 1 inwhich said insulating means comprises a plastic material which isextruded onto the metal strip in the flat before the strip is formedinto the channel.
 8. An edge guard as set forth in claim 7 in which saidnon-metallic layer also comprises plastic material, and the plasticmaterials are co-extruded onto opposite surfaces of the metal strip inthe flat.
 9. In an ornamental and protective edge guard of generallychannel-shaped cross section comprising inner and outer legs via whichthe edge guard is self-retaining on the edge of a sheet metal panel of avehicle body when the edge guard is installed thereon, the edge guardcomprising a metal strip formed to a generally channel-shaped crosssection with the sides of the channel constituting the legs of the edgeguard, and an insulating layer secured to the metal strip, theimprovement comprising a bead at the distal end of one leg comprising adouble thickness fold of the metal strip folded back onto the one leg sothat there are three thicknesses of metal at the distal end of the oneleg and said bead also comprising at least two thicknesses of saidinsulating layer wherein the two thicknesses of insulating layer are notin surface-to-surface confrontation with each other but wherein one ofthe two thicknesses of insulating layer is disposed on the distal end ofthe leg so as to insulate the metal of the strip from that of the sheetmetal panel, and in which said insulating material is selectivelydisposed on both sides of the metal strip which become the majorportions of the exterior and interior of the channel-shaped crosssection and covers the entirety of each of said sides.
 10. In anornamental and protective edge guard of generally channel-shaped crosssection comprising inner and outer legs via which the edge guard isself-retaining on the edge of a sheet metal panel of a vehicle body whenthe edge guard is installed thereon, the edge guard comprising a metalstrip formed to a generally channel-shaped cross section with the sidesof the channel constituting the legs of the edge guard, and aninsulating layer secured to the metal strip, the improvement comprisinga bead at the distal end of one leg comprising a double thickness foldof the metal strip folded back onto the one leg so that there are threethicknesses of metal at the distal end of the one leg and said bead alsocomprising at least two thicknesses of said insulating layer wherein thetwo thicknesses of insulating layer are not in surface-to-surfaceconfrontation with each other but wherein one of the two thicknesses ofinsulating layer is disposed on the distal end of the leg so as toinsulate the metal of the strip from that of the sheet metal panel, andin which insulating material is selectively applied to the metal stripsuch that in the finished edge guard, insulating material covers bothinterior and exterior of the cross section so that none of the metal oneither the interior or exterior of the cross section is exposed to view.11. In combination with the trailing edge of a swinging metal closure ona vehicle, which trailing edge in closed position of the swinging metalclosure, is separated from an adjacent panel of the vehicle by a gap, anedge guard fitting onto the trailing edge comprising a metal stripformed into a channel having an interior side and an exterior side andcomprising a base and inner and outer legs extending from said base forapplying a self-retention force against opposite sides of the trailingedge, insulating means disposed between said channel and the trailingedge at least along the force-applying points of the legs for insulatingthe metal of the edge guard channel from that of the trailing edge, andbeads integral with and at the distal ends of said legs, at least one ofsaid beads comprising a double thickness fold of the metal strip foldedback onto the corresponding leg so that three thicknesses of metalresult at the force-applying point of that leg and wherein the combinedthicknesses of said strip and of said insulating means at said base areless than the thickness of said gap, and including further insulatingmeans disposed on the surface of said strip which forms the majority ofthe exterior side of said channel covering the corresponding leg atleast between the double thickness fold and the base.
 12. In anornamental and protective edge guard of generally channel-shaped crosssection comprising inner and outer legs via which the edge guard isself-retaining on the edge of a sheet metal panel of a vehicle body whenthe edge guard is installed thereon, the edge guard comprising a metalstrip having opposite surfaces which respectively form the majority ofthe interior of the channel-shaped cross section and the majority of theexterior of the channel-shaped cross section, said strip being formed toa generally channel-shaped cross section with the sides of the channelconstituting the legs of the edge guard, and an insulating layer securedto the metal strip, the improvement comprising a bead at the distal endof one leg comprising a double thickness fold of the metal strip foldedback onto the one leg so that there are three thicknesses of metal atthe distal end of the one leg and said bead also comprising at least twothicknesses of said insulating layer wherein the two thicknesses ofinsulating layer are not in surface-to-surface confrontation with eachother but wherein one of the two thicknesses of insulating layer isdisposed on the distal end of the leg so as to insulate the metal of thestrip from that of the sheet metal panel, and in which the otherthickness of insulating layer is disposed on the metal strip's surfacewhich is opposite the surface of the metal strip on which the onethickness of insulating layer is disposed.